U.S. patent application number 10/985269 was filed with the patent office on 2006-05-11 for yarn manufacturing apparatus and method.
Invention is credited to Kenneth H. Keith.
Application Number | 20060096270 10/985269 |
Document ID | / |
Family ID | 36314912 |
Filed Date | 2006-05-11 |
United States Patent
Application |
20060096270 |
Kind Code |
A1 |
Keith; Kenneth H. |
May 11, 2006 |
Yarn manufacturing apparatus and method
Abstract
The present invention is an apparatus and method of making yarn
for carpet that exhibits a high degree of color pop. More
specifically, in one aspect, the present invention comprises an
apparatus and method that comprises supplying a plurality of yarns,
false-twist the plurality of yarns, and passing the consolidated
yarn through a downstream entangling assembly to tack at least a
portion of the consolidated yarn. Another aspect of the present
invention passes at least one of the plurality of yarns through one
of a plurality of second entangling assemblies positioned upstream
of the false-twist apparatus.
Inventors: |
Keith; Kenneth H.;
(Chatsworth, GA) |
Correspondence
Address: |
NEEDLE & ROSENBERG, P.C.
SUITE 1000
999 PEACHTREE STREET
ATLANTA
GA
30309-3915
US
|
Family ID: |
36314912 |
Appl. No.: |
10/985269 |
Filed: |
November 10, 2004 |
Current U.S.
Class: |
57/205 |
Current CPC
Class: |
D01H 7/90 20130101; D02G
1/0226 20130101; D02G 1/024 20130101; D02G 1/0206 20130101; D02G
3/445 20130101; D02J 1/08 20130101; D01H 7/92 20130101 |
Class at
Publication: |
057/205 |
International
Class: |
D02G 3/36 20060101
D02G003/36; D02G 3/02 20060101 D02G003/02 |
Claims
1. A yarn false-twist assembly, comprising: a body member having a
first end, an opposed second end, and a central longitudinal axis,
the body member defining a central bore extending co-axial to the
central longitudinal axis therebetween the first and second ends
and a plurality of second bores extending parallel to the central
longitudinal axis therebetween the first and second ends, each
second bore being spaced from the central bore; and a driver
constructed and arranged to rotate the body member in an
oscillating motion so as to impart a false-twist into each yarn
passing through each of at least two second bores about an at least
one yarn passing through the central bore to form a consolidated
yarn.
2. The yarn false-twist assembly of claim 1, further comprising
means for passing the yarn through each of at least two of the
second bores of the body member and means for feeding the at least
one yarn through the central bore of the body member.
3. The false-twist assembly of claim 1, wherein the plurality of
second bores of the body member comprises four (4) or less second
bores.
4. The false-twist assembly of claim 1, wherein the plurality of
second bores of the body member comprises eight (8) or less second
bores.
5. The false-twist assembly of claim 1, wherein the plurality of
second bores of the body member comprises twelve (12) or less
second bores.
6. The false-twist assembly of claim 1, wherein the driver
oscillates the body member about the central longitudinal axis in a
first direction and an opposite second direction, and wherein the
body member rotates from about 45.degree. to about 300.degree. in
both the first and second directions.
7. The false-twist assembly of claim 1, wherein the driver
oscillates the body member about the central longitudinal axis in a
first direction and an opposite second direction, and wherein the
body member rotates from about 90.degree. to about 270.degree. in
both the first and second directions.
8. The false-twist assembly of claim 1, wherein the driver
oscillates the body member about the central longitudinal axis in a
first direction and an opposite second direction, and wherein the
body member rotates about 180.degree. in both the first and second
directions.
9. The false-twist assembly of claim 1, wherein each of the
plurality of second bores is spaced from the central bore a
predetermined radial distance.
10. The false-twist assembly of claim 9, wherein each of the
plurality of second bores is spaced from the central bore
substantially the same radial distance.
11. The false-twist assembly of claim 1, wherein the body member
has an exterior peripheral surface, wherein the body member has a
plurality of gear teeth extending outwardly away from the
peripheral surface and about at least a portion of the peripheral
surface.
12. The false-twist assembly of claim 11, wherein the driver
operatively engages the plurality of gear teeth.
13. The false-twist assembly of claim 11, wherein the gear teeth
extend in a plane substantially normal to the central longitudinal
axis.
14. The false-twist assembly of claim 1, wherein the body member is
substantially cylindrically shaped.
15. A yarn manufacturing apparatus, comprising: a) a false-twist
assembly, comprising: i) a body member having a first end, an
opposed second end, and a central longitudinal axis, the body
member defining a central bore extending co-axial to the central
longitudinal axis therebetween the first and second ends and a
plurality of second bores extending parallel to the central
longitudinal axis therebetween the first and second ends, each
second bore being spaced from the central bore; and ii) a driver
constructed and arranged to rotate the body member in an
oscillating motion so as to impart a false-twist into each yarn
passing through each of at least two second bores about an at least
one yarn passing through the central bore to form a consolidated
yarn; and b) a first entangling assembly for tacking at least a
portion of the consolidated yarn as the consolidated yarn passes
therethrough the first entangling assembly, the first entangling
assembly being positioned downstream of the second end of the body
member.
16. The yarn manufacturing apparatus of claim 15, wherein the
driver oscillates the body member about the central longitudinal
axis in a first direction and an opposite second direction, and
wherein the body member rotates from about 45.degree. to about
300.degree. in both the first and second directions.
17. The yarn manufacturing apparatus of claim 15, wherein the
driver oscillates the body member about the central longitudinal
axis in a first direction and an opposite second direction, and
wherein the body member rotates from about 90.degree. to about
270.degree. in both the first and second directions.
18. The yarn manufacturing apparatus of claim 15, wherein the
driver oscillates the body member about the central longitudinal
axis in a first direction and an opposite second direction, and
wherein the body member rotates about 180.degree. in both the first
and second directions.
19. The yarn manufacturing apparatus of claim 15, wherein each of
the plurality of second bores is spaced from the central bore a
predetermined radial distance.
20. The yarn manufacturing apparatus of claim 19, wherein each of
the plurality of second bores is spaced from the central bore
substantially the same radial distance.
21. The yarn manufacturing apparatus of claim 15, wherein the first
entangling assembly comprises an air tacking jet positioned
adjacent a flow path of the consolidated yarn through the first
entangling assembly, and wherein the air tacking jet directs an air
stream onto at least a portion of the consolidated yarn.
22. The yarn manufacturing apparatus of claim 15, further
comprising at least one second entangling assembly being positioned
upstream of the first end of the body member, wherein at least one
yarn is passed through the at least one second entangling assembly
prior to the communication of the at least one yarn to the body
member, and wherein each second entangling assembly tacks at least
a portion of the yarn that passes therethrough the respective
second entangling assembly.
23. The yarn manufacturing apparatus of claim 22, wherein each
second entangling assembly comprises an air tacking jet positioned
adjacent a flow path of the yarn through the second entangling
assembly, and wherein the air tacking jet directs an air stream
onto at least a portion of the yarn.
24. The yarn manufacturing apparatus of claim 15, wherein the yarns
comprise at least two colors.
25. The yarn manufacturing apparatus of claim 24, wherein at least
one of the yarns of the at least one yarn fed into the central bore
has a different color than the color of the yarn fed into the
second bores.
26. A method of manufacturing yarn, comprising: supplying a
plurality of yarns; providing a false-twist assembly, comprising a
body member having a first end, an opposed second end, and a
central longitudinal axis, the body member defining a central bore
extending co-axial to the central longitudinal axis therebetween
the first and second ends and a plurality of second bores extending
parallel to the central longitudinal axis therebetween the first
and second ends, each second bore being spaced from the central
bore; and rotating the body member in an oscillating motion so as
to impart a false-twist into each yarn passing through each of at
least two second bores about an at least one yarn passing through
the central bore to form a consolidated yarn.
27. The method of claim 26, further comprising passing the yarn
through each of at least two of the second bores of the body
member; and passing the at least one yarn through the central bore
of the body member.
28. The method of claim 26, further comprising winding up the
consolidated yarn.
29. The method of claim 26, further comprising, after forming the
consolidated yarn, passing the consolidated yarn through a first
entangling assembly to tack at least a portion of the consolidated
yarn.
30. The method of claim 26 or 29, further comprising, after
supplying a plurality of yarns, passing at least one yarn of the
plurality of yarns through a second entangling assembly to tack at
least a portion of the yarn.
31. The method of claim 30, wherein the second entangling assembly
comprises a plurality of second entangling assemblies, and wherein
each second entangling assembly of the plurality of second
entangling assemblies tacks one individual yarn of the plurality of
yarns.
32. The method of claim 26, wherein all of the plurality of yarns
are passed through the false-twist assembly.
33. The method of claim 26, wherein the plurality of yarns comprise
at least two colors.
34. The method of claim 33, wherein at least one of the yarns of
the at least one yarn fed into the central bore has a different
color than the color of the yarn fed into the second bores.
35. The method of claim 26, wherein each of the plurality of yarns
have a denier of from about 150 to about 9,000.
36. The method of claim 26, wherein the consolidated yarn has a
denier of from about 300 to about 15,000.
37. A yarn formed from the process comprising: supplying a
plurality of yarns; providing a false-twist assembly, comprising a
body member having a first end, an opposed second end, and a
central longitudinal axis, the body member defining a central bore
extending co-axial to the central longitudinal axis therebetween
the first and second ends and a plurality of second bores extending
parallel to the central longitudinal axis therebetween the first
and second ends, each second bore being spaced from the central
bore; and rotating the body member in an oscillating motion so as
to impart a false-twist into each yarn passing through each of at
least two second bores about an at least one yarn passing through
the central bore to form a consolidated yarn.
38. The yarn formed by the process of claim 37, further comprising
winding up the consolidated yarn.
39. The yarn formed by the process of claim 37, further comprising,
after forming the consolidated yarn, passing the consolidated yarn
through a first entangling assembly to tack at least a portion of
the consolidated yarn.
40. The yarn formed by the process of claim 37 or 39, further
comprising, after supplying a plurality of yarns, passing at least
one yarn of the plurality of yarns through a second entangling
assembly to tack at least a portion of the yarn.
41. The yarn formed by the process of claim 40, wherein the second
entangling assembly comprises a plurality of second entangling
assemblies, and wherein each second entangling assembly of the
plurality of second entangling assemblies tacks one individual yarn
of the plurality of yarns.
42. The yarn formed by the process of claim 37, wherein all of the
plurality of yarns pass through the false-twist assembly.
43. The yarn formed by the process of claim 37, wherein the
plurality of yarns comprise at least two colors.
44. The yarn formed by the process of claim 43, wherein at least
one of the yarns of the at least one yarn fed into the central bore
has a different color than the color of the yarn fed into the
second bores.
45. The yarn formed by the process of claim 37, wherein each of the
plurality of yarns have a denier of from about 150 to about
9,000.
46. The yarn formed by the process of claim 37, wherein the
consolidated yarn has a denier of from about 300 to about
15,000.
47. The yarn formed by the process of claim 37, wherein the yarn
passing through the central bore is from about 5% to about 95%, by
weight, of the formed consolidated yarn.
48. The yarn formed by the process of claim 37, wherein the yarn
passing through the central bore is from about 15% to about 80%, by
weight, of the formed consolidated yarn.
49. The yarn formed by the process of claim 37, wherein the yarn
passing through the central bore is from about 25% to about 60%, by
weight, of the formed consolidated yarn.
50. A carpet comprising a consolidated yarn of claim 37.
51. A carpet comprising a consolidated yarn of claim 39.
52. A carpet comprising a consolidated yarn of claim 40.
53. A yarn manufacturing apparatus, comprising: a) a false-twist
assembly, comprising: i) a body member having a first end, an
opposed second end, and a central longitudinal axis, the body
member defining a plurality of bores extending parallel to the
central longitudinal axis therebetween the first and second ends,
each bore being spaced from the central longitudinal axis; and ii)
a driver constructed and arranged to rotate the body member in an
oscillating motion so as to impart a false-twist into each yarn
being passed into each of at least two bores of the plurality of
bores to form a consolidated yarn; and b) a first entangling
assembly to tack at least a portion of the consolidated yarn as the
consolidated yarn passes therethrough the first entangling
assembly, the first entangling assembly being positioned downstream
of the second end of the body member.
54. The yarn manufacturing apparatus of claim 53, further
comprising means for feeding a yarn through each of at least two of
the bores of the body member.
55. The yarn manufacturing apparatus of claim 53, wherein the
driver oscillates the body member about the central longitudinal
axis in a first direction and an opposite second direction, and
wherein the body member rotates from about 45.degree. to about
300.degree. in both the first and second directions.
56. The yarn manufacturing apparatus of claim 53, wherein the
driver oscillates the body member about the central longitudinal
axis in a first direction and an opposite second direction, and
wherein the body member rotates from about 90.degree. to about
270.degree. in both the first and second directions.
57. The yarn manufacturing apparatus of claim 53, wherein the
driver oscillates the body member about the central longitudinal
axis in a first direction and an opposite second direction, and
wherein the body member rotates about 180.degree. in both the first
and second directions.
58. The yarn manufacturing apparatus of claim 53, wherein each of
the plurality of bores is spaced from the central longitudinal axis
a predetermined radial distance.
59. The yarn manufacturing apparatus of claim 58, wherein each of
the plurality of bores is spaced from the central longitudinal axis
substantially the same radial distance.
60. The yarn manufacturing apparatus of claim 53, wherein the first
entangling assembly comprises an air tacking jet positioned
adjacent a flow path of the consolidated yarn through the first
entangling assembly, and wherein the air tacking jet directs an air
stream onto at least a portion of the consolidated yarn.
61. The yarn manufacturing apparatus of claim 53, further
comprising at least one second entangling assembly being positioned
upstream of the first end of the body member, at least one yarn
passing through the second entangling assembly prior to the
communication of the at least one yarn to the body member to tack
at least a portion of the yarn that passes therethrough the second
entangling assembly.
62. The yarn manufacturing apparatus of claim 61, wherein the
second entangling assembly comprises an air tacking jet positioned
adjacent a flow path of the yarn through the second entangling
assembly, and wherein the air tacking jet directs an air stream
onto at least a portion of the yarn.
63. The yarn manufacturing apparatus of claim 53, wherein the yarns
comprise at least two colors.
64. A method of manufacturing yarn, comprising: supplying a
plurality of yarns; providing a false-twist assembly, comprising a
body member having a first end, an opposed second end, and a
central longitudinal axis, the body member defining a plurality of
bores extending parallel to the central longitudinal axis
therebetween the first and second ends, each bore being spaced from
the central longitudinal axis; and rotating the body member in an
oscillating motion so as to impart a false-twist into each yarn
being passed through each of at least two bores to form a
consolidated yarn.
65. The method of claim 64, further comprising winding up the
consolidated yarn.
66. The method of claim 64, further comprising, after forming the
consolidated yarn, passing the consolidated yarn through a first
entangling assembly to tack at least a portion of the consolidated
yarn.
67. The method of claim 64 or 66, further comprising, after
supplying a plurality of yarns, passing at least one yarn of the
plurality of yarns through one of a plurality of second entangling
assemblies to tack at least a portion of the yarn.
68. The method of claim 67, wherein each second entangling assembly
of the plurality of second entangling assemblies tacks one
individual yarn of the plurality of yarns.
69. The method of claim 64, wherein all of the plurality of yarns
pass through the false-twist assembly.
70. The method of claim 64, wherein the plurality of yarns comprise
at least two colors.
71. The method of claim 64, wherein each of the plurality of yarns
have a denier of from about 150 to about 9000.
72. The method of claim 64, wherein the consolidated yarn has a
denier of from about 300 to about 15,000.
73. A yarn formed from the process comprising: supplying a
plurality of yarns; providing a false-twist assembly, comprising a
body member having a first end, an opposed second end, and a
central longitudinal axis, the body member defining a plurality of
bores extending parallel to the central longitudinal axis
therebetween the first and second ends, each bore being spaced from
the central longitudinal axis; and rotating the body member in an
oscillating motion so as to impart a false-twist into each yarn
being passed through each of at least two bores to form a
consolidated yarn.
74. The yarn formed from the process of claim 73, further
comprising winding up the consolidated yarn.
75. The yarn formed from the process of claim 73, further
comprising, after forming the consolidated yarn, passing the
consolidated yarn through a first entangling assembly to tack at
least a portion of the consolidated yarn.
76. The yarn formed from the process of claim 73 or 75, further
comprising, after supplying a plurality of yarns, passing at least
one yarn of the plurality of yarns through a second entangling
assembly to tack at least a portion of the yarn.
77. The yarn formed from the process of claim 76, wherein the
second entangling assembly comprises a plurality of second
entangling assemblies; and wherein each second entangling assembly
of the plurality of second entangling assemblies tacks one
individual yarn of the plurality of yarns.
78. The yarn formed from the process of claim 73, wherein all of
the plurality of yarns pass through the false-twist assembly.
79. The yarn formed from the process of claim 73, wherein the
plurality of yarns comprise at least two colors.
80. The yarn formed from the process of claim 73, wherein each of
the plurality of yarns have a denier of from about 150 to about
9,000.
81. The yarn formed from the process of claim 70, wherein the
consolidated yarn has a denier of from about 300 to about
15,000.
82. A carpet comprising a consolidated yarn of claim 73.
83. A carpet comprising a consolidated yarn of claim 75.
84. A carpet comprising a consolidated yarn of claim 76.
85. A method of manufacturing yarn, comprising: supplying a
plurality of yarns; false-twist the plurality of yarns; and passing
the consolidated yarn through a first entangling assembly to tack
at least a portion of the consolidated yarn.
86. The method of claim 85, further comprising winding up the
consolidated yarn.
87. The method of claim 85, further comprising, after supplying a
plurality of yarns, passing at least one yarn of the plurality of
yarns through one of a plurality of second entangling assemblies to
tack at least a portion of the yarn.
88. The method of claim 85, wherein each second entangling assembly
of the plurality of second entangling assemblies tacks one
individual yarn of the plurality of yarns.
89. The method of claim 85, wherein the plurality of yarns comprise
at least two colors.
90. The method of claim 85, wherein each of the plurality of yarns
have a denier of from about 150 to about 9000.
91. The method of claim 85, wherein the consolidated yarn has a
denier of from about 300 to about 15,000.
Description
FIELD OF THE INVENTION
[0001] The present invention pertains to the field of continuous
synthetic filaments, and particularly, to yarns comprised of
multiple continuous filaments. In some embodiments, the present
invention pertains to yarns suitable for the production of
carpets.
BACKGROUND OF INVENTION
[0002] Carpet manufacturers are continually searching for yarns
which provide distinct visual appearance when converted into cut,
loop pile or cut-loop pile carpet structures. For example,
continuous filament carpet yarns which provide an appearance to the
final carpet structure showing distinct and separate colors have
achieved widespread popularity. The distinct appearance of
different colors in the carpet is commonly referred to as "color
pop."
[0003] One of the main issues with this process is that it is
difficult to obtain a good quality yarn with a high degree of color
pop. When the air pressure of the entangling jets is sufficient
enough to impart substantially uniformly spaced bulked portions and
tacks, the colors of the individual yarns may be muted and lose
their individual characteristics.
[0004] On the other hand, if a high degree of color pop is desired,
the air pressure of the entangling jets would be reduced, thereby
not allowing the individual yarns to get overly entangled. The
resulting color pop turns out to be very good, but the yarn may
include and a high degree of streaking. Consequently, there is a
need for an apparatus and method of manufacturing yarn that to
reduces streaking while at the same time enhancing color pop.
SUMMARY
[0005] The present invention addresses the problems in the art and
minimizes streaking when a large denier yarn is tufted into a
carpet. Additionally, it provides an apparatus and method of making
yarn for carpet that exhibits a high degree of color pop. More
specifically, in one aspect, the present invention comprises a yarn
manufacturing apparatus and method that comprises supplying a
plurality of yarns, false-twist the plurality of yarns, and passing
the consolidated yarn through a first entangling assembly to tack
at least a portion of the consolidated yarn. In another aspect, the
invention comprises passing at least one of the plurality of yarns
through one or more second entangling assemblies upstream of the
false-twist apparatus.
[0006] False-twisting the yarns prior entangling them into a
consolidated yarn enhances color pop in the resulting consolidated
yarn by changing the order that the yarns are fed into the first
entangling assembly. Constantly changing the feed order of the
yarns into the first entangling assembly reduces the possibility of
one yarn riding on top of the others.
[0007] In another embodiment, the yarn manufacturing apparatus
comprises a yarn false-twist assembly that has a body member with a
first end, an opposed second end, and a central longitudinal axis.
One aspect of the body member defines a plurality of second bores
that extend longitudinally from the first end to the second end.
Each of the second bores are spaced from the central longitudinal
axis. In another aspect, the body member defines a central bore
that extends longitudinally, co-axial to the central longitudinal
axis, therebetween the first and second ends.
[0008] In one aspect of the invention, the false-twist assembly has
a driver constructed and arranged to rotate the body member in an
oscillating fashion so as to impart a false-twist into each yarn
being fed into each of the second bores. If yarn is feed through
the central bore, then the yarn passing through the second bores
are false twisted about the yarn passing through the central bore
to form a consolidated yarn.
DETAILED DESCRIPTION OF THE DRAWINGS
[0009] The patent or application file contains at least one drawing
executed in color. Copies of this patent or patent application
publication with color drawing(s) will be provided by the Office
upon request and payment of the necessary fee.
[0010] These and other features of the preferred embodiments of the
present invention will become more apparent in the detailed
description in which reference is made to the appended drawings
wherein:
[0011] FIG. 1 is a schematic view of one embodiment of a yarn
manufacturing apparatus of the present invention showing a
false-twist assembly disposed in the flow path between a first
entangling assembly and a second entangling assembly.
[0012] FIG. 2 is a partial perspective view of one aspect of a body
member of a false-twist assembly being oscillated about a
longitudinal axis by a driver.
[0013] FIG. 2A is a perspective cross-sectional view of the body
member taken across line 2A of FIG. 2.
[0014] FIG. 3 is a partial perspective view of one aspect of a body
member of a false-twist assembly being oscillated about a
longitudinal axis by a driver.
[0015] FIG. 3A is a perspective cross-sectional view of the body
member taken across line 3A of FIG. 3.
[0016] FIGS. 4, 5, and 6 color photographs of carpet samples,
particularly, FIGS. 4A, 5A and 6A show carpet samples using
conventional yarn, and FIGS. 4B, 5B and 6B show carpet samples
using yarn manufactured by the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention is more particularly described in the
following exemplary embodiments that are intended as illustrative
only since numerous modifications and variations therein will be
apparent to those skilled in the art. As used herein, "a," "an," or
"the" can mean one or more, depending upon the context in which it
is used. The preferred embodiments are now described with reference
to the figures, in which like reference characters indicate like
parts throughout the several views.
[0018] Ranges may be expressed herein as from "about" one
particular value, and/or to "about" another particular value. When
such a range is expressed, another embodiment includes from the one
particular value and/or to the other particular value. Similarly,
when values are expressed as approximations, by use of the
antecedent "about," it will be understood that the particular value
forms another embodiment.
[0019] In one aspect, the present invention provides a continuous
yarn manufacturing apparatus and method. In one aspect of the
invention, a yarn false-twist assembly 10 is provided that
comprises a body member 100 that has a first end 110, an opposed
second end 120, and a central longitudinal axis L. The body member
100 of this embodiment defines a plurality of second bores 130 that
extend longitudinally substantially parallel to the central
longitudinal axis L therebetween the first and second ends. Each of
these second bores 130 is spaced from the central longitudinal axis
L. In another aspect, the body member can define a central bore 140
that extends longitudinally therebetween the first and second ends
substantially co-axial to the central longitudinal axis L.
Additionally, in one aspect of this embodiment, the body member 100
is substantially cylindrical.
[0020] The false-twist assembly 10 also comprises a means for
passing a yarn through each of the second bores 130. If the body
member has a central bore 140, the false-twist assembly may also
comprise a means for feeding at least one yarn through the central
bore of the body member. As one skilled in the art would
appreciate, there are a number of conventional means for feeding
the yarn through the bores of the body member. It has been
contemplated to manually feed the yarn ends through the assembly
and to use a mechanical winder 50 to pull the yarns through the
false-twist assembly 10. Also, the yarns can be fed using drive
rolls (not shown) upstream of the false-twist assembly 10.
[0021] In one aspect, there is a pair of drive rolls being driven
in a counterclockwise direction. The surface of the drive rolls can
be made of a hardened aluminum alloy or the like, and can be
slightly textured, but still relatively smooth. In this aspect, the
yarn passes from a yarn tensioning device and conventionally around
the rolls.
[0022] In another aspect, the false-twist assembly 10 comprises a
driver constructed and arranged to rotate the body member in an
oscillating motion about the central longitudinal axis L of the
body member 100 so as to impart a false-twist into each yarn 200
being fed into each of the second bores 130. In one example, the
yarns 200 fed into each of the second bores 130 are false-twisted
about the yarn or yarns 210 fed through the central bore to form a
consolidated yarn 230. As one skilled in the art would appreciate,
any conventional driver for rotating the body member about the
central longitudinal axis is contemplated. For example, the driver
can include, but is not limited to, a drive gear, a drive belt, a
direct drive motor, and the like.
[0023] In one example, the body member 100 of the false-twist
assembly 10 has an exterior peripheral surface 150. In this aspect,
the body member has a plurality of gear teeth 160 extending
outwardly away from the peripheral surface 150 and about at least a
portion of the peripheral surface. In another aspect, the gear
teeth 160 extend in a plane substantially normal to the central
longitudinal axis L.
[0024] In yet another aspect of the false-twist assembly 10, the
driver operatively engages the plurality of gear teeth on the
exterior peripheral surface of the body member. As one skilled in
the art can appreciate, this driver can be, but is not limited to,
many common gear assemblies, including spur gears, worm gears,
bevel gears, helical gears, rack and pinion gears, and the
like.
[0025] In one aspect of the false-twist assembly 10, the driver can
be a quarter spur gear attached to a cam device. The cam device
can, in turn, be attached to a drive motor.
[0026] In one aspect of the false-twist assembly 10, the driver
oscillates the body member about the central longitudinal axis L in
a first direction and a second, opposite, direction from about
45.degree. and about 300.degree. in both directions. In another
aspect, the driver oscillates the body member from about 90.degree.
and 270.degree. in both directions. In still another aspect, the
driver oscillates the body member about 180.degree. in both
directions.
[0027] The existence of the central bore 140 in the body member 100
of the false-twist assembly 10 makes it possible to false-twist the
yarns 200 that are fed through the second bores about the yarn 210
fed through the central bore 140. It will be appreciated that the
yarn 210 fed through the central bore 140 receives no
false-twist.
[0028] In another aspect of the present embodiment, the body member
100 of the false-twist assembly comprises four (4) or less second
bores. In yet another aspect, the body member comprises eight (8)
or less second bores. Still, in another aspect, the body member
comprises twelve (12) or less second bores. One will appreciate
however, that any select number of second bores are
contemplated.
[0029] In another aspect of the present embodiment, the plurality
of second bores 130 are spaced from the central longitudinal axis L
a predetermined radial distance. In another aspect, each of the
plurality of second bores 130 is spaced from the central
longitudinal axis L the same predetermined radial distance. It is
contemplated however, that the second bores can be positioned at
varying distances from the central longitudinal axis. In one
example, the second bores are staggered such that adjacent second
bores are spaced differing distances from the central longitudinal
axis of the body member 100.
[0030] One embodiment of the yarn manufacturing apparatus of the
present invention comprises a false-twist assembly 10 described
above and a first entangling assembly 20. As noted, the false-twist
assembly 10 described above can have a central bore 140 that
provides the ability to false-twist yarns about a central yarn(s),
thereby having a "core" yarn that would be central to the resulting
consolidated yarn. However, the present invention will work without
the central bore 140. As those skilled in the art could appreciate,
any conventional false-twist devices can be used to impart a
false-twist in the plurality of yarns. Examples of conventional
false-twist devices include false-twist air jets such as those made
by Barco, Temco, Belmont, Gilbos and others. Other examples of
conventional false-twist devices may include mechanical devices,
such as the device depicted in U.S. Pat. No. 4,377,932, which is
herein incorporated by reference. As one skilled in the art can
appreciate, any device that will impart a false twist into the
plurality of yarns will suffice.
[0031] In one aspect of the false-twist assembly, the first
entangling assembly 20 tacks at least a portion of the consolidated
yarn 220 as the consolidated yarn passes therethrough the first
entangling assembly 20. The first entangling assembly is positioned
downstream of the false-twist assembly. In one example, the first
entangling assembly is positioned downstream of the second end 120
of the body member 100. The first entangling assembly can comprise
a conventional air tacking jet positioned adjacent and/or along the
flow path of the consolidated yarn 220 through the first entangling
assembly. In this example, the air tacking jet directs an air
stream onto at least a portion of the consolidated yarn. When the
yarns emerge from the tacking jet, the yarns have been entangled so
that there is a plurality of bulked portions along the yarn,
separated by areas in which the yarns are tacked together. Examples
of the air tacking jets include jets, such as those made by Barco,
Temco, Belmont, Gilbos and others. The first entangling assembly
can also comprise, for example and not limited to, a
hydro-entangler, a hydraulic entangler, an ultrasonic entangler, or
the like.
[0032] Another aspect of the yarn manufacturing process further
comprises a plurality of second entangling assemblies 30 positioned
upstream of the false-twist assembly 10. In one example, each
second entangling assembly 30 is positioned upstream of the first
end 110 of the body member 100. In this aspect, at least one yarn
passes through the plurality of second entangling assemblies 30
prior to the communication of the yarn to the false-twist assembly
10. Each second entangling assembly 30 of the yarn manufacturing
process tacks at least a portion of the yarn that passes through
the respective second entangling assembly. Similarly to the first
entangling assembly, the second entangling assemblies 30 can
comprise an air tacking jet positioned adjacent and/or along a flow
path of the yarn through the second entangling assembly. In this
aspect, the air tacking jet directs an air stream onto at least a
portion of the yarn. Examples of the air tacking jets include jets,
such as those made by Barco, Temco, Belmont, Gilbos and others. The
second entangling assemblies can also comprise, for example and not
limited to, a hydro-entangler, a hydraulic entangler, an ultrasonic
entangler, or the like.
[0033] In another aspect of the yarn manufacturing apparatus of
this embodiment, the yarns 200 comprise at least two colors. In yet
another aspect, in which the false-twist assembly defines a central
bore 140 and a plurality of second bores 130, at least one of the
yarns of the at least one yarn 210 fed into the central bore has a
different color than the color of the yarn 200 fed into the second
bores.
[0034] Another embodiment of the invention is a method of
manufacturing yarn comprising supplying a plurality of yarns.
Generally, the yarns are fed to the process from a creel 40, from
one or more knit socks, or from any other means known in the art.
In one example, the supplied yarns pass through appropriate guide
means (not shown), then to a tensioning means (not shown). The
tensioning means can be a pair of disks, one disk being urged
towards the other by spring means so that the variation of spring
tension will vary the tension on the yarns. Such a tensioning
device is well known to those skilled in the art. Any tensioning
means known to those skilled in the art would be appropriate.
[0035] The supplied yarn is then fed into a false-twist assembly
10. As mentioned previously, the false-twist assembly can be
identical to the false-twist assembly described herein above (with
or without the central bore), or it can be any of a number of false
twisting assemblies known in the art. The false-twist assembly
described above, with the second bores 130 and the central bore 140
defined in the body member 100, provides the ability to false-twist
yarns about a central yarn 210, which would be substantially at the
core of the resulting consolidated yarn.
[0036] Next, the plurality of yarns are false-twisted. In an aspect
of this embodiment, in which the false-twist assembly defines the
plurality of second bores and the central bore, the method
comprises feeding a yarn through each of at least two of the second
bores of the body member of the false-twist assembly and feeding at
least one yarn through the central bore of the body member. The
body member 100 of the false-twist assembly 10 is rotated in an
oscillating motion so as to impart the false-twist into each yarn
200 being fed into each of the at least two second bores 130 about
at least one yarn 210 fed through the central bore 140 to form a
consolidated yarn 220. In one aspect, at least one yarn fed into
the central bore can have a different color than the color of the
yarn fed into the second bores.
[0037] In one aspect of the method, the yarn passing through the
central bore is from about 5% to about 95%, by weight, of the
formed consolidated yarn. In another aspect, the yarn passing
through the central bore is from about 15% to about 80%, by weight,
of the formed consolidated yarn. In yet another aspect, the yarn
passing through the central bore is from about 25% to about 60%, by
weight, of the formed consolidated yarn.
[0038] In an alternative aspect, in which the false-twist assembly
10 described above has a plurality of bores 130 and no central
bore, the method comprises feeding a yarn through at least two of
the bores of the body member of the false-twist assembly. The
method further comprises rotating the body member of the
false-twist assembly in an oscillating motion so as to impart a
false twist into each yarn being fed into each of the at least two
bores to form a consolidated yarn 220.
[0039] False-twist a multi-colored yarn prior to entangling
enhances color pop in a resulting carpet made from such yarn by
alternating the sequence of the respective colors going through the
entangling process, thereby disallowing one particular color from
riding on top of the other color(s) in the consolidated yarn.
[0040] In one example of this method, after forming the
consolidated yarn, the yarn is passed through a first entangling
assembly 20 to tack at least a portion of the consolidated yarn
220. As mentioned above, tacking the consolidated yarns forms a
plurality of bulked portions along the yarn, separated by areas in
which the yarns are tacked together.
[0041] In one aspect of this method, the method further comprises,
after supplying a plurality of yarns, passing at least one yarn of
the plurality of yarns through one or more second, upstream,
entangling assemblies 30 to tack at least a portion of the yarn. As
can be appreciated by one skilled in the art, all of the plurality
yarns can be passed through second entangling assemblies. That is,
each yarn can pass through its own particularly assigned second
entangling assembly.
[0042] Tacking the individual yarns prior to subjecting them to a
false-twist step assists in keeping the filaments of the individual
yarns together. In this way, the separate yarns retain their
individual characteristics when formed into a consolidated yarn.
This is especially noticeable when the plurality of yarns comprises
at least two colors.
[0043] In one aspect of the method, each yarn of the plurality of
yarns has a denier of from about 150 and 9,000. In yet another
aspect, the consolidated yarn passing out of the first, downstream,
entangling assembly has a denier of from about 300 and 15,000.
These ranges are approximate and are not to be considered a
limitation to the method of manufacturing yarn herein
described.
[0044] In another aspect of this embodiment, the method includes
winding up the consolidated yarn for future use. The consolidated
yarn can then be used in the manufacture of a variety of carpet
types.
[0045] Although several embodiments of the invention have been
disclosed in the foregoing specification, it is understood by those
skilled in the art that many modifications and other embodiments of
the invention will come to mind to which the invention pertains,
having the benefit of the teaching presented in the foregoing
description and associated drawings. It is thus understood that the
invention is not limited to the specific embodiments disclosed
herein above, and that many modifications and other embodiments are
intended to be included within the scope of the appended claims.
Moreover, although specific terms are employed herein, as well as
in the claims which follow, they are used only in a generic and
descriptive sense, and not for the purposes of limiting the
described invention, nor the claims which follow.
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